Dyno Report : Evo Highflow Intake Kit on Boxster S

[clubhead]

Results as follow :

Horsepower (at the wheels)
Base run with Dansk headers/Dansk Sports Cat/Dansk Sports Muffler : 239.6bhp @ 6,499rpm
Run with addon Evo Highflow Intake Kit : 241.6rpm @ 6,606rpm
Gain : 2bhp at about 6,500rpm

Torque (at the wheels)
Base run with Dansk headers/Dansk Sports Cat/Dansk Sports Muffler : 139.1kg/m @ 4,877rpm
Run with addon Evo Highflow Intake : 140kg/m @ 4,998rpm
Gain : 1kg/m at about 4,900rpm

The fuel used for all dyno is 100 Octane as this is available from most pumps locally. The dyno graph is attached. Red is the run with the intake.

An air temp probe was installed before/after the change. I'm using deg Celsius over here so resulted in the double digit for deg Fahrenheit after conversion. So it's not that I'm using a super accurate temp sensor A picture of the sensor is attached for reference. Cost me about US$15. The following were noted :

Original Stock Intake (Ambient Temp : 89.6 deg F according to in-dash display)
Car stationary for 1 min with engine running :
- 102.74 to 104.18 (1.43 deg F increase)
- 104.54 to 105.44 (0.9 deg F increase)

Car stationary for 1 min with engine not running :
- 106.34 to 114.26 (7.92 deg F increase)

Car in motion at about 55mph for 1 min :
- Generally 6.3 deg F above ambient temp if engine was started from cold
- Generally 10 deg F above ambient temp if engine was hot when started

Evo Highflow Intake (Ambient Temp : 91.4 deg F according to in-dash display)
Car stationary for 1 min with engine running :
- 105.44 to 121.46 (16.02 deg F increase)
- 112.46 to 129.02 (16.56 deg F increase)

Car stationary for 1 min with engine not running :
- Similar to above

Car in motion at about 55mph for 1 min :
- Generally 2.7 deg F above ambient temp if engine was started from cold
- Generally 5.4 deg F above ambient temp if engine was hot when started

If anyone is interested to know how hot the engine bay gets, the temp sensor reads 153 deg F after letting the car sit for about 40 mins.

Observations :
- bhp was down everywhere except about 2,000rpm and 6,500rpm
- bhp drop is significant at 3,000rpm
- torque was down bet 2,500 to 4,800rpm and 6,100 to 6,400rpm
- Drop in torque is significant at 3,000rpm, about 5kg/m
- Air temp increase significant during traffic even with heat shield, 1 deg F vs 16 deg F increase
- Air temp generally lower when car is cruising

The stock air box is a real PITA to remove. The intake manifold needs to be loosened and even then, pulling the airbox out was no easy task still.

Needless to say, I'm unhappy with the overall results. I think the car is still somewhat better compared to a completely stock one but for the money spent till now, the past 2 mods (muffler & intake) have yielded negative results.

Some suggested in another posting that my poor results could be due to either a bad MAF or air leakage from loose fitting. I've checked all the hoses and fasteners today and found all to be tight. I doubt a bad MAF as my idling is steady across all rpms.

So now, I'm assuming a ECU is necessary to benefit from all this mods. Anyone with comments on GIAC? I'm thinking of taking that route but will need to live without my car for 1 week as I need to send the ECU to a dealer to get it re-programmed

[jwocky]

It shouldn't take 1 week for the reprogramming. Overnight it to them, they flash upgrade it within minutes and can then overnight it back. Whole thing can be done in 3 days.

[Brucelee]

Sadly, I was chatting with my service tech at the local dealer about Box mods in general. He said their exprience with their customers is one of general disappointment with things such as intakes, exhausts, chips etc.

Not to throw water on all this, it is just that I wish some of these after market parts makers would back up their claims with a money back guarantee.

If you say it is going to generate more HP, it seems to me that you should stand behind that claim!

Good luck with this!

[Lux]

Interesting. Looking at your temps, there is a significant increase in temp when the car at idle. This definitely is attributing to your low numbers just off idle. Looks like the stock airbox does well in insulating the engine heat. It's kinda weird that the Evo shows a lower temp at 55mph than stock though. You would expect that since the stock airbox insulates better at standstill, it should be lower in temp at 55mph also...unless it is still storing heat. But you've also tested running to 55mph from start (cold I assume?) so that kinda rules it out. Regardless, it looks like both are running around the same temps at 55mph...94-96 degrees.

Before going to GIAC, you should get your a/f measured. And not with the sensor that goes in the tailpipe as that is not very accurate. You'll have to drill into your headers pre-cat and attach the sensor there. Afterall, if your a/f looks fine, then the issue is with the intake. If your a/f is out of whack, then at least you know you need the GIAC.

[clubhead]

Originally Posted by Lux

Before going to GIAC, you should get your a/f measured. And not with the sensor that goes in the tailpipe as that is not very accurate. You'll have to drill into your headers pre-cat and attach the sensor there. Afterall, if your a/f looks fine, then the issue is with the intake. If your a/f is out of whack, then at least you know you need the GIAC.

That's something to consider. My Dansk manifold already has a pre-drilled hole for the factory O2 sensor that came with 2002 and above cars. That'll save me the trouble of drilling and welding.

Anyway, my local mechanic has suggested that perhaps, the supplied K&N filter is too small and may be a reason for a lower bhp reading. Basically, smaller surface area for intake will result in less air. I'm going to remove the filter next week and replace it with a VERY fine wire mesh over the intake tube. Go for dyno and see the results. If the dyno reading is higher, then his theory will be right.

And by the way, I made sure during dyno, the intake temp was normalised to about 45 deg C in both before/after runs... So that removes the air temp factor during the run.

[Adam]

I hope you go for the GIAC Clubehead because nobody on here has it as far as I know. I am interested in possibly upgrading someday but I don't want to be the guinnie pig. GIAC has done wonders for other cars, so I'm willing to bet the gains will be worth time and money.

[clubhead]

Originally Posted by jwocky

It shouldn't take 1 week for the reprogramming. Overnight it to them, they flash upgrade it within minutes and can then overnight it back. Whole thing can be done in 3 days.

Only problem is I'm half a world away from USA So courier is going to take longer than usual...

[sharkster]

This is really great feedback but without an ECU/flash you're probably running lean with just those mods. You really do need to tune for mods like that- especially an intake. We have a couple of S' in the shop right now that we're doing the same upgrades you did but we're flashing the cars with GIAC's software and expect roughly 44HP more to the crank- that's what we've seen in the past.

Originally Posted by clubhead

Results as follow :

Horsepower (at the wheels)
Base run with Dansk headers/Dansk Sports Cat/Dansk Sports Muffler : 239.6bhp @ 6,499rpm
Run with addon Evo Highflow Intake Kit : 241.6rpm @ 6,606rpm
Gain : 2bhp at about 6,500rpm

Torque (at the wheels)
Base run with Dansk headers/Dansk Sports Cat/Dansk Sports Muffler : 139.1kg/m @ 4,877rpm
Run with addon Evo Highflow Intake : 140kg/m @ 4,998rpm
Gain : 1kg/m at about 4,900rpm

The fuel used for all dyno is 100 Octane as this is available from most pumps locally. The dyno graph is attached. Red is the run with the intake.

An air temp probe was installed before/after the change. I'm using deg Celsius over here so resulted in the double digit for deg Fahrenheit after conversion. So it's not that I'm using a super accurate temp sensor A picture of the sensor is attached for reference. Cost me about US$15. The following were noted :

Original Stock Intake (Ambient Temp : 89.6 deg F according to in-dash display)
Car stationary for 1 min with engine running :
- 102.74 to 104.18 (1.43 deg F increase)
- 104.54 to 105.44 (0.9 deg F increase)

Car stationary for 1 min with engine not running :
- 106.34 to 114.26 (7.92 deg F increase)

Car in motion at about 55mph for 1 min :
- Generally 6.3 deg F above ambient temp if engine was started from cold
- Generally 10 deg F above ambient temp if engine was hot when started

Evo Highflow Intake (Ambient Temp : 91.4 deg F according to in-dash display)
Car stationary for 1 min with engine running :
- 105.44 to 121.46 (16.02 deg F increase)
- 112.46 to 129.02 (16.56 deg F increase)

Car stationary for 1 min with engine not running :
- Similar to above

Car in motion at about 55mph for 1 min :
- Generally 2.7 deg F above ambient temp if engine was started from cold
- Generally 5.4 deg F above ambient temp if engine was hot when started

If anyone is interested to know how hot the engine bay gets, the temp sensor reads 153 deg F after letting the car sit for about 40 mins.

Observations :
- bhp was down everywhere except about 2,000rpm and 6,500rpm
- bhp drop is significant at 3,000rpm
- torque was down bet 2,500 to 4,800rpm and 6,100 to 6,400rpm
- Drop in torque is significant at 3,000rpm, about 5kg/m
- Air temp increase significant during traffic even with heat shield, 1 deg F vs 16 deg F increase
- Air temp generally lower when car is cruising

The stock air box is a real PITA to remove. The intake manifold needs to be loosened and even then, pulling the airbox out was no easy task still.

Needless to say, I'm unhappy with the overall results. I think the car is still somewhat better compared to a completely stock one but for the money spent till now, the past 2 mods (muffler & intake) have yielded negative results.

Some suggested in another posting that my poor results could be due to either a bad MAF or air leakage from loose fitting. I've checked all the hoses and fasteners today and found all to be tight. I doubt a bad MAF as my idling is steady across all rpms.

So now, I'm assuming a ECU is necessary to benefit from all this mods. Anyone with comments on GIAC? I'm thinking of taking that route but will need to live without my car for 1 week as I need to send the ECU to a dealer to get it re-programmed

[clubhead]

Originally Posted by sharkster

We have a couple of S' in the shop right now that we're doing the same upgrades you did but we're flashing the cars with GIAC's software and expect roughly 44HP more to the crank- that's what we've seen in the past.

44bhp? Hmmm.... we'll see about that when my ECU returns from Evo Have a feeling that's a bit optimistic. Right now, I'm just hoping to gain back my street drivability (low to mid range) which is where I'm suffering now...

[sharkster]

Originally Posted by clubhead

44bhp? Hmmm.... we'll see about that when my ECU returns from Evo Have a feeling that's a bit optimistic. Right now, I'm just hoping to gain back my street drivability (low to mid range) which is where I'm suffering now...

When tuned right you can really eke out some decent number... as I said that wasn't WHP but crank HP

[Adam]

Hey Sharky just wanted to say you have one incredible ride. I saw your car over on racing flix several mo back. Gotta love a 996TT that can do low 10's. I'm sure you're probably in the 9's now. Thx for coming by boxsterville.

[sharkster]

Originally Posted by Adam

Hey Sharky just wanted to say you have one incredible ride. I saw your car over on racing flix several mo back. Gotta love a 996TT that can do low 10's. I'm sure you're probably in the 9's now. Thx for coming by boxsterville.

Heya Adam, thanks for the kind words... The car is so different these days, it's more set up for the road course now but I've done some more stuff to it recently and intend to go back to see what she runs. I think 9s is gonna be very very tough It was hard enough to get into the 10s but I doubt she'll go 9s but we'll see.

I get to drive Boxster S' all the time and love 'em... I almost got the 987 but I figured I'm going to wait for the cayman. I know the name sucks but damn that is going to be one great car.